Multi-dimensional fiber composites and articles using the same

ABSTRACT

A composite down-hole tool for use in oil and gas wells includes plurality of fibers which extend along at least a first fiber plane and a second fiber plane. The first fiber plane and the second fiber plane are arranged perpendicular. A matrix material substantially fills the area between and around the plurality of fibers. The down-hole tool is spherical or cylindrical and substantially all of the plurality of fibers extend substantially straight and uninterrupted between opposed sides of the spherical or cylindrical shape down-hole tool.

RELATED APPLICATIONS

This application is a continuation-in-part of International ApplicationNo. PCT/US14/30982, filed on Mar. 18, 2014, entitled “Multi-DimensionalFiber Composites and Articles Using the Same,” which claims priority toUS Provisional App. No. 61/816,307, filed on Apr. 26, 2013 and USProvisional App. No. 61/929,526, filed on Jan. 21, 2014 of which areincorporated herein by reference. The benefit of priority to theaforementioned applications is hereby claimed under at least 35 U.S.C.§365.

BACKGROUND

Fiber composite materials are widely used in a variety of applications.In particular, woven composites are increasingly useful due toexceptional strength and other properties that may be tailored to aparticular application. However, prior art fiber composite materials maysuffer from limitations including constrained thru-thickness, andstrengths that are not adequate for certain extreme environments suchas, for example, down-hole tools for use in the oil and gas industry.Accordingly, there is a need in the art for improved fiber compositematerials and down-hole tools employing the same.

brief description

According to one aspect, a composite down-hole tool includes a pluralityof fibers. The fibers extend along at least a first fiber plane and asecond fiber plane. The first fiber plane and the second fiber plane arearranged perpendicular. A matrix material substantially fills the areabetween and around the plurality of fibers. The down-hole tool isspherical or cylindrical and substantially all of the plurality offibers extend substantially straight and uninterrupted between opposedsides of the spherical or cylindrical shape down-hole tool.

Another embodiment disclosed herein includes a down-hole tool formedfrom a plurality of layers of fabric. Each layer may include fiberswoven in at least two (2) directions (AKA dimensions). A matrix materialmay at least substantially fill an area between adjacent fibers andbetween adjacent fabric layers. The down-hole tool may have a sphericalor cylindrical shape.

DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is an isometric view of a three dimensional preform;

FIG. 2 is a front view of the preform of FIG. 1;

FIG. 3 is a larger isometric view of a three dimensional preform;

FIG. 4 is a top view of a four dimensional preform;

FIG. 5 is a side view of the preform of FIG. 4;

FIG. 6 is an isometric view of a the preform of FIG. 4;

FIG. 7 is a top view of a five dimensional preform;

FIG. 8 is a side view of the preform of FIG. 7;

FIG. 9 is an isometric view of the preform of FIG. 7;

FIG. 10 is a top view of an alternate four dimensional preform;

FIG. 11 is an isometric view of a cylindrical preform; and

FIG. 12 is an isometric view of a frac ball.

DETAILED DESCRIPTION

With reference to FIG. 1, a composite material is generally indicated bythe numeral 10. The composite 10 includes a fiber reinforcement 12 and amatrix material (not shown for clarity). The fiber reinforcement 12includes a plurality of fibers (either individual or bunched) 14 indistinct orientations. As used in the present disclosure a fiber plane16 includes a plurality of individual fibers 14 aligned in a commonplane and direction and having a generally constant center-to-centerspacing. In a particularly advantageous embodiment, fibers in a fiberplane have a substantially equal center-to-center spacing throughout anentire fiber plane. As should also be appreciated, each composite 10includes a plurality of each fiber plane 16 in a repeating stackedconfiguration.

Fibers 14 may include any number of fiber materials that providestructural reinforcement to the composite material. For example, fibers14 may be carbon fibers and particularly PAN carbon fibers, glassfibers, aramid fibers (e.g. Kevlar® produced by DuPont), PEEK fibers(polyether ether ketone), PPS fibers (polyphenylene sulfide), PEN fibers(polyethylene naphalate), basalt fibers and combinations thereof. Fiber14 is not limited to any particular tow size. A range of tow sizes ofparticular interest may range from about 1K to about 30K. Examples ofparticular tow sizes under consideration include 1K, 3K, 5K, 8K, 12K,15K, 18K, 21K, 24K and 30K. The various tow sizes may be usedindependently of one another in any particular embodiment or in anycombination thereof in any particular embodiment.

The matrix material fills substantially the entire area between andaround the fibers in composite material 10, 100, 200, 300, and 400.Matrix material must be flowable to enable the impregnation of the fiberplanes. The matrix material is selected based on the desiredperformance, operating temperature, compressive strength, processingcharacteristics, chemical stability, porosity, and density. Exemplarymatrix materials include epoxies, polyester resin, vinyl ester, cyanateester, polyimides, phenolic, engineering thermal plastics, PEEK(polyetheretherketone), PPS (polyphenylene sulfide), PS (polysufone),Torlon® (polyamide-imide), Nylon6/6, Nylon 11 benzoxazine, ceramic,pitch and combinations thereof. Matrix material advantageously includesa room temperature compressive strength of at least 3.0 kPsi, still moreadvantageously at least 5.0 kPsi, still more advantageously at least 15kPsi, and still more advantageously at least 20 kPsi. In otherembodiments, the matrix material includes a compressive strength of frombetween about 5 kPsi and about 25 kPsi. In further embodiments, thematrix material includes a compressive strength of from between about 10kPsi and about 20 kPsi. The amount of matrix material in composite 14may vary from embodiment to embodiment as desired.

Optionally the matrix material may include a reinforcement. Examples ofthe reinforcement include multi-walled carbon nanotubes, single walledcarbon nanotubes, graphene particles and combinations thereof. Theamount of reinforcement included in the matrix may include up to tenpercent (10%) by weight of the resin (“bwr”), no more than five percent(5%) bwr, no more than three percent (3%) bwr, no more than two percent(2%) bwr, or no more than one percent (1%) bwr.

The down-hole tool, to be discussed in greater detail below,advantageously includes a matrix material having a temperaturecapability of at least about 200° F., and more advantageously at leastabout 300° F., and even further more advantageously at least about 350°F. By temperature capability, it is meant that the matrix material maybe heated to the above temperature without melting or otherwise becomingsubstantially structurally degraded during the required service period.In particular, epoxies and polyimide matrix materials exhibitparticularly advantageous characteristics for down-hole tools.

Refer again to the composite preform of FIG. 1, wherein the referencedirections x, y and z are shown. As shall be discussed in greater detailbelow, the fiber composition of the composite preform of FIG. 1 isreferred to as three dimensional, because the fibers extend in threedistinct fiber directions. Thus, for example, the composite materialshown in FIG. 1 includes a first fiber orientation 14 a, a second fiberorientation 14 b and a third fiber orientation 14 c. The fibers 14 alying on the same plane form a first fiber plane 16 a, the fibers 14 blying on the same plane form a second fiber plane 16 b and the fibers 14c lying on the same plane form a third fiber plane 16 c. As can be seen,first fiber plane 16 a and 16 b are parallel to the x-y plane and have afiber direction offset from each other by 90 degrees. The fibers 14 c,forming third fiber plane 16 c, are oriented perpendicular to the x-yplane.

Within each fiber plane, individual fibers are oriented in the samedirection and on the same plane and may have a center-to-center spacingfrom between about 0.035 inches to about 0.500 inches. In furtherembodiments, the center-to-center spacing may be from between about0.069 inches to about 0.2 inches. The first fiber plane 16 a and secondfiber plane 16 b are arranged parallel to the X-Y plane and in thecomposite material 10 are layered in an alternating stacked arrangement.Third fiber plane 16 c transects first and second fiber planes 16 a and16 b. In one embodiment, an aperture 17 is formed by adjacent fibers infiber plane 16 a and over-laid adjacent fibers of fiber plane 16 b, andeach aperture 17 advantageously receives a fiber from fiber plane 16 cthere through. As can be seen, composite material 10 includes aplurality of third fiber planes 16 c, positioned in a stackedarrangement.

Advantageously, fiber planes 16 a and 16 b are spaced at a substantiallyconstant distance from each other. In other embodiments, the fibers 14 aand 14 b forming fiber planes 16 a and 16 b are layered and in directcontact. For purposes of the present disclosure, two adjoining fiberplanes 16 a and 16 b are referred to as a fiber layer 20. In this orother embodiments, the number of layers per inch (hereinafter LPI) maybe from between about 1 LPI to about 50. In further embodiments, the LPImay be from between about 5.0 and about 15. In still furtherembodiments, the LPI may be from between about 8.0 and about 35. Thecomposite material includes a plurality of repeating fiber planesdistributed throughout the entire article. For example, first and secondfiber planes 16 a and 16 b repeat in a stacked arrangement in the zdirection for the entire height of the composite material. Similarly,the third fiber plane 16 c repeats in the y direction for the entirewidth of the composite material.

As shown if FIGS. 1-3, fibers 14 of composite material 10 extendsubstantially straight for the entire length of the composite material10. In the illustrated embodiment , the fiber weave does not include anycrimps and are not interwoven to form a sine or wave shape. Further,advantageously at least 95 percent, more advantageously at least 99percent, and still more advantageously substantially all of fibers 14extend substantially straight and uninterrupted between opposed sides ofthe composite material. Thus, in this manner no fiber loops or crimpsare included in the article. Likewise, the uniform composition withuninterrupted fibers improves strength and structural integrity of thecomposite material, and thus any subsequently produced article.

In a particular embodiment, the fibers of composite 10 may be orientedin a two dimensions (“2-D”), three dimensions (“3-D”) or more than 3-D.

With reference to FIGS. 4-6, a composite material 100 is shown andgenerally indicated by the numeral 100. As shall be discussed in greaterdetail below, the fiber composition of the composite material of FIGS.4-6 is referred to as four dimensional, because the fibers extend infour distinct directions. Thus, the composite material shown in FIG. 4includes a first fiber orientation 114 a, a second fiber orientation 114b, a third fiber orientation 114 c and a fourth fiber orientation 114 d.As can be seen, first fibers 114 a lying on the same plane form firstfiber plane 116 a, second fibers 114 b lying on the same plane formsecond fiber plane 116 b, third fibers 114 c lying on the same planeform a third fiber plane 116 c, and fourth fibers 114 d lying on thesame plane form a fourth fiber plane 116 d. First, second and thirdfiber orientations 114 a, 114 b and 114 c are parallel to the x-y planeand have a fiber direction offset from each other by 60 degreesrespectively. The fourth fibers 114 d forming fourth fiber plane 116 dare oriented perpendicular to the x-y plane. Within each fiber plane,individual fibers are oriented on the same plane and direction and mayhave a center-to-center spacing from between about 0.042 inches to about0.500 inches. In further embodiments, the center-to-center spacing maybe from between about 0.062 inches to about 0.200 inches. The firstfiber plane 116 a, second fiber 116 b plane and third fiber plane 116 care arranged parallel to the X-Y plane and are positioned in analternating stacked arrangement in the z direction. Fourth fiber plane116 d transects first, second, and third fiber planes 116 a, 116 b and116 c. In one embodiment, an aperture 117 is formed by adjacent fibersin the three over-laid fiber planes 116 a, 116 b and 116 c.Advantageously, each aperture 117 receives a fiber from a fiber plane116 d there through.

Advantageously, fiber planes 116 a, 116 b, and 116 c are spaced at asubstantially constant distance from each other. In this or otherembodiments, the fibers 114 a, 114 b and 114 c of adjacent fiber planes116 a, 116 b and 116 c are layered and in direct contact. For purposesof the present disclosure, a set of three adjoining fiber planes 116 a,116 b and 116 c parallel to the X-Y plane are referred to as fiber layer120. In this or other embodiments, the number of layers per inch(hereinafter LPI) may be from between about 1 LPI to about 30 LPI. Infurther embodiments, the LPI may be from between about 5.0 and about 15.In still further embodiments, the LPI may be from between about 4.0 andabout 12. The composite material 100 includes a plurality of repeatingfiber planes distributed throughout the entire article. For example,first, second and third fiber planes 116 a, 116 b, and 116 c repeat in astacked arrangement in the z direction for the entire height of thecomposite material. Similarly, the fourth fiber plane 116 d repeats inthe y direction for the entire width of the composite material.

As shown if FIGS. 4-6, fibers 114 of composite material 100 extendsubstantially straight for the entire length of the composite material100. In other words, the fiber weave does not include any crimps and arenot interwoven to form a sine or wave shape. Further, advantageously atleast 95 percent, more advantageously at least 99 percent, and stillmore advantageously substantially all of fibers 114 extend uninterruptedbetween opposed sides of the composite material. Thus, in this manner nofiber loops or crimps are included in the article. Likewise, the uniformcomposition with uninterrupted fibers improves strength and structuralintegrity of the composite material, and thus any subsequently producedarticle.

With reference now to FIGS. 7-9, a preform composite material is shownand generally indicated by the numeral 200. As shall be discussed ingreater detail below, the fiber composition of the composite material ofFIG. 7-9 is referred to as five dimensional, because the fibers extendin five distinct directions. Thus, the composite material includes afirst fiber orientation 214 a, a second fiber orientation 214 b, a thirdfiber orientation 214 c, a fourth fiber orientation 214 d, and a fifthfiber orientation 214 e. As can be seen, first fiber orientation 214 alying on the same plane forms a first fiber plane 216 a, second fiberorientation 214 b lying on the same plane forms a second fiber plane 216b, third fiber orientation 214 c laying on the same plane forms a thirdfiber plane 216 c and fourth fiber orientation 214 d laying on the sameplane forms a fourth fiber plane 216 d. Fibers 214 a, 214 b, 214 c and214 d are parallel to the x-y plane and have a fiber direction offsetfrom each other by 60 degrees respectively. Fifth fiber orientation 214e laying on the same plane forms a fifth fiber plane 216 e and isoriented perpendicular to the x-y plane.

Within each fiber plane, individual fibers are oriented on the sameplane and direction and may have a center-to-center spacing from betweenabout 0.042 inches to about 0.500 inches. In other embodiments, thecenter-to-center spacing may be from between about 0.42 inches to about0.200 inches. The first fiber plane 216 a, second fiber 216 b plane,third fiber plane 216 c and fourth fiber plane 216 d are arrangedparallel to the X-Y plane and are positioned in a repeating alternatingpattern. Fifth fiber plane 216 e transects first, second, third andfourth fiber planes 216 a, 216 b, 216 c and 216 d. In one embodiment, anaperture 217 is formed by adjacent fibers in the four over-laid fiberplanes fiber plane 216 a, 216 b, 216 c and 216 d. Advantageously, eachaperture 217 receives a fiber from a fiber plane 216 e there through.

Advantageously, fiber planes 216 a, 216 b, 216 c and 216 d are spaced ata substantially constant distance from each other. In other embodiments,the fibers 214 a, 214 b, 214 c and 214 d are stacked adjacent to eachother and in direct contact. For purposes of the present disclosure,four adjoining fiber planes 216 a, 216 b, 216 c and 216 d are parallelto the X-Y plane and are referred to as a fiber layer 220. In this orother embodiments, the number of layers per inch (hereinafter LPI) maybe from between about 1 LPI to about 30 LPI. In other embodiments, thenumber of layers per inch may be from between about 4 LPI and about 12LPI. The composite material 200 includes a plurality of repeating fiberplanes distributed throughout the entire article. For example, first,second, third and fourth fiber planes 216 a, 216 b, 216 c and 216 drepeat in a stacked arrangement in the z direction for the entire heightof the composite material. Similarly, the fifth fiber plane 116 erepeats in the y direction for the entire width of the compositematerial.

As shown if FIGS. 7-9, fibers 214 of composite material 200 extendsubstantially straight for the entire length of the composite material200. In other words, the fiber weave does not include any crimps and arenot interwoven to form a sine or wave shape. Further, advantageously atleast 95 percent, more advantageously at least 99 percent, and stillmore advantageously substantially all of fibers 214 extend uninterruptedbetween opposed sides of the composite material. Thus, in this manner nofiber loops or crimps are included in the article. Likewise, the uniformcomposition with uninterrupted fibers improves strength and structuralintegrity of the composite material, and thus any subsequently producedarticle.

With reference now to FIG. 10, a composite material is shown andgenerally indicated by the numeral 300. As shall be discussed in greaterdetail below, the fiber composition of the composite material of FIG. 10is referred to as four dimensional, because the fibers extend in fourdistinct directions. However, the composite 300 differs from thecomposite 100 in that each of the first fiber plane 316 a formed byfibers 314 a, second fiber plane 316 b formed by fibers 314 b, thirdfiber plane 316 c formed by fibers 314 c and fourth fiber plane 316 dformed by fibers 314 d (appearing to extend out of the paper) extend ina distinct direction and none of the fiber planes are parallel toanother fiber plane. Within each fiber plane, individual fibers areoriented on the same plane and direction and may have a repeatingcenter-to-center spacing from between about 0.042 inches to about 0.500inches. In other embodiments, the center-to-center spacing may be frombetween about 0.42 inches to about 0.200 inches. Because of theunaligned nature of the composite material 300, each fiber layer willtransect the other three fiber layers. The composite material 300includes a plurality of repeating fiber planes distributed throughoutthe entire article. Specifically, each of fiber planes 316 a, 316 b, 316c, and 316 d repeats in a direction perpendicular to the respectiveplane for the entire width/length of the composite material.

As shown in FIG. 10, fibers 314 of preform composite 300 extendsubstantially straight for the entire length of the preform composite300. In other words, the fiber weave does not include any crimps and arenot interwoven to form a sine or wave shape. Further, advantageously atleast 95 percent, more advantageously at least 99 percent, and stillmore advantageously substantially all of fibers 314 extend uninterruptedbetween opposed sides of the composite material. Thus, in this manner nofiber loops or crimps are included in the article. The uniformcomposition with uninterrupted fibers improves strength and structuralintegrity of the composite and likewise any subsequently producedarticle.

The three, four and five dimensional composite materials describedhereinabove may be produced in considerably larger dimensions thantraditional woven composites. Advantageously, the composite materialsmay be produced having a z-direction height of at least 12.0 inches,more advantageously at least 18 inches, and still more advantageously atleast 24 inches tall and still more advantageously at least 36 inchestall. In further embodiments, the z-direction height may be from betweenabout 6 inches and about 36 inches. In this or other embodiments, the xand y direction lengths may be greater than at least 4 inches, stillmore advantageously at least 12 inches and still more advantageously atleast 24 inches. In this or other embodiments, the x and y directionlengths may be from between about 12 inches and about 24 inches.

Compressive strength of the composite material described here in aboveis principally dependent on fiber volume and direction. In oneembodiment, the composite material compressive strength may bedetermined based on a compressive strength factor times the fiber volumeextending in the direction of measurement. Thus, for example, for acomposite material having 10 percent fiber volume extending in thez-direction, the compressive strength may be determined in thez-direction by multiplying 0.10 times a compressive strength factor forthe selected fiber or reinforcement. In one embodiment, the compressivestrength factor is from between about 170 ksi and about 530 ksi. Instill other embodiments the compressive strength factor is from betweenabout 250 ksi and about 400 ksi. In still other embodiments, thecompressive strength factor is greater than about 170 ksi. In otherembodiments the compressive strength factor is greater than about 250ksi. And in still further embodiments, the compressive strength factoris greater than about 380 ksi.

Tensile strength of the composite material described hereinabove isdependent on fiber volume and direction. In one embodiment, thecomposite material tensile strength may be determined based on a tensilestrength factor times the fiber volume extending in the direction ofmeasurement. Thus, for example, for a composite material having 10percent fiber volume extending in the z-direction the tensile strengthmay be determined in the z-direction by multiplying 0.10 times a tensilestrength factor. In one embodiment, the tensile strength factor is frombetween about 220 ksi and about 690 ksi. In still other embodiments thetensile strength factor is from between about 300 ksi and about 550 ksi.In still other embodiments, the tensile strength factor is greater thanabout 220 ksi. In other embodiments the tensile strength factor isgreater than about 290 ksi.

With the following information a composites engineer of ordinary skillin the art would be able to determine the compressive strength factor orthe tensile strength factor for the composite material: (1) type offiber; (2) fiber properties e.g., compressive strength, tensilestrength, shear strength, and modulus; (3) matrix material; (4) fibervolume; and (5) the fabric is “straight yarn.”

With reference now to FIG. 11, a composite material is shown andgenerally indicated by the numeral 400. Composite material 400 differsfrom the above described composites in that not all fibers are straightand not all fibers extend from between opposed sides of the material.Composite 400 is generally cylindrical shaped and includescircumferentially extending fibers 414, radially extending fibers 414 b,and axially extending fibers 414 c. Individual layer planes 416 a ofcircumferentially extending fibers 414 a lay on the same plane and growradially larger from an inner radial surface to the outer radial surfaceof composite 400. Individual layer planes 416 b of radially extendingfibers 414 b lay on the same plane and extend radially outward and areangularly offset about the diameter of the cylinder.

For purposes of the present disclosure, one circumferentially extendingfiber layer 416 a and radially extending fiber layer 416 b are referredto as a fiber layer 420. In this or other embodiments, the number oflayers per inch (hereinafter LPI) may be from between about 0.5 LPI toabout 30 LPI. Center-to-center spacing of circumferentially extendingfibers 416 a (in the radial direction) may be from between about 0.025″to about 0.500″. More advantageously, center-to-center spacing of thecircumferentially extending fibers 416 a may be from between about0.065″ and about 0.330″. The center-to-center spacing of radiallyextending fibers 416 b (in the circumferential direction) may be frombetween 0.035″ and about 0.700″. In other embodiments, thecenter-to-center spacing of radially extending fibers (in thecircumferential direction) may be from between about 0.065″ and about0.330″. Advantageously, the layers per inch are substantially constantthrough the axial length of the preform 400. However, it should beappreciated that the center-to-center spacing of the radially extendingfibers is dependent on the radial distance from the centerline of thecylinder. In other words, the further from the centerline of thecylinder, the larger the center-to-center spacing of the radiallyextending fibers.

The circumferential fiber plane 416 a and radial fiber plane 416 b arearranged parallel to the X-Y plane and are positioned in an alternatingstacked arrangement in the z direction. Axially extending fibers 414 ctransect the radial and circumferential fiber planes 416 a and 416 b. Inone embodiment, an aperture 417 is formed by adjacent fibers in the twoover-laid fiber planes 416 a and 416 b. Advantageously, each aperture117 receives at least one axially extending fiber 416 c there through.The composite material 400 includes a plurality of repeating fiberplanes distributed throughout the entire article. For example,circumferential fiber plane 416 a and radial fiber plane 416 b repeat ina stacked arrangement in the z direction for the entire height of thecomposite material. Similarly, the axially extending fibers 414 c arerepeat in the radial and circumferential directions, advantageouslypositioned between each adjacent circumferential fiber 414 a and betweeneach adjacent radial fiber 414 b.

The composite materials described herein above may be constructed withfiber volumes, as defined by the relationship between actual fibervolume and overall part volume, from between about 15% to about 55%. Infurther embodiments, and as may be particularly advantageous fordown-hole tools, the fiber volume may be from between about 30% andabout 43%. In one embodiment, the fiber volume for each fiber directionis substantially the equivalent. In this embodiment, the compositematerial includes at least 5 percent fiber volume, more advantageouslyat least 8 percent fiber volume, and still more advantageously at least10 percent fiber volume in each fiber direction. In a particularlypreferred embodiment for the down-hole tool described herein below, a 3dimensional composite includes from between about 5 and about 15 percentfiber volume in each of the x, y and z direction, and moreadvantageously from between about 8 and about 12 percent fiber volume ineach of the x, y and z direction. In other embodiments, the fibervolumes for one or more of the fiber directions may be different,resulting in varied physical properties depending on orientation of thecomposite material.

Advantageously, the density of the composite material may be frombetween about 0.90 g/cc to about 2.00 g/cc. In a further embodiment, andone particularly advantageous for a down-hole tool, the overallcomposite density may be from between about 1.20 g/cc to about 1.8 g/cc.In further embodiments, the composite material has a density of lessthan about 1.8 g/cc, and more advantageously less than about 1.5 g/cc,and still more advantageously less than about 1.2 g/cc.

It should be appreciated that, for each of the above compositematerials, in one embodiment a single fiber type is used for all fiberplanes. In another embodiment, one or more of the fiber planes mayinclude different fiber types from the other fiber planes. For example,the fibers in a fiber plane oriented along a z-axis may include a firsttype of fiber and the fiber planes oriented parallel to an x-y plane mayinclude a second type of fiber. In still a further embodiment, eachfiber plane may include a different fiber type.

With reference now to FIG. 12 a down-hole tool, is generally indicatedby the numeral 500. Down-hole tool may be made from any of the abovedescribed composite materials.

Down-hole tool 500 is particularly suitable for, and adapted for use, inunderground oil and gas applications. In one embodiment, down-hole toolis a frac ball which is sized to be dropped or pumped into an oil or gaswell to be received in a seat (not shown). In this manner, sections ofthe well may be sealed off from other sections so that certaintreatments or functions may be performed. Accordingly, to facilitatesealing, down-hole tool 500 is substantially spherical. In otherembodiments, the down-hole tool 500 is substantially ovoid or eggshaped. In still further embodiments, down-hole tool is generallycylindrical in shape. In an additional embodiment, the down-hole tool500 may have an oval cross section. Down-hole tool 500 may have adiameter of from between about 0.5 inches to about 8.0 inches. Ifdown-hole tool is egg or ovoid shaped, the down-hole tool may have anaxial length from between about 2.0 inches to about 12.0 inches. Ifdown-hole tool is cylindrical shaped, the diameter may be at least twoinches, in other embodiments at least 4 inches, and in still otherembodiments at least 6 inches. If down-hole tool is a cylindrical shape,the axial length may be at least 6 inches, in other embodiments at least12 inches, and in still other embodiments at least 24 inches.

Down-hole tool 500 may advantageously be made of any of the abovedescribed composite materials. In one particular embodiment, down-holetool 500 is sphere shaped, includes a 3 dimensional fiber structure asdescribed hereinabove. Therefore, the tool 500 and includes fibersextending straight and uninterrupted to opposed sides of the tool alongat least two perpendicular planes. Advantageously, the two perpendicularplanes transect the largest diameter of the down-hole tool. In oneembodiment, the down-hole tool includes at least one of PAN based carbonfibers and/or E and/or S glass fibers and includes epoxy or polyimide asthe matrix material. Down-hole tool 500 advantageously withstands wellpressures of greater than 10,000 psi, still more advantageously greaterthan 12,000 psi, and still more advantageously greater than 15,000 psiwithout being extruded into the seat or otherwise failing.

Another embodiment disclosed herein includes a down-hole tool formedfrom a plurality of layers of fabric. Each layer may include fiberswoven in at least two (2) directions (AKA dimensions). A matrix materialmay at least substantially fill an area between adjacent fibers andbetween adjacent fabric layers. The down-hole tool may have a sphericalor cylindrical shape. Just to avoid any doubt, the above descriptionregarding the matrix material and the reinforcement, are equallyapplicable to this embodiment also.

In a particular embodiment, the fabric layers may be constructed fromfibers having more than one sized fiber tow. For example, the size offiber tow used to make one or more fabric layers of the compositearticle may range from 1000 to 30000. One preferred upper end sizedfiber tow is 24000 (“24K”). In a different embodiment, each fabric layeris made from one sized fiber tow, but adjacent fiber layers are not madefrom the same sized tow.

The fabric layer is not limited to one style of weave. Individual fabriclayers may be constructed of at least one of the following weave styles:twill style weave, a plain weave or a unidirectional weave. Theplurality of fabric layers may all have the same weave style, adifferent weave style or any combination thereof.

The composite article may be constructed from a billet. The billet maybe formed from a plurality of woven fabric layers laid one on top of theother. If so desired the adjacent individual fabric layers maybe laidparallel to one another, perpendicular to one another, thereby creatingan isotropic billet. In an different embodiment, the adjacent fabriclayers may be oriented about sixty 60°) degrees (at least 50° to no morethan 70°) from each other.

In one advantageous embodiment of the above graphite article, thearticle will have a water absorption (AKA moisture absorption) of lessthan three (3%) percent, preferably less than two (2%) percent, morepreferably less than one (1%) percent and even more preferably less thanhalf (0.5%) percent. ASTM standard D 570 may be used to determine thewater absorption exhibited by the graphite article.

The above description is intended to enable the person skilled in theart to practice the invention. It is not intended to detail all thepossible variations and modifications that will become apparent to theskilled worker upon reading the description. It is intended, however,that all such modifications and variations be included within the scopeof the invention that is defined by the following claims. Thus, althoughthere have been described particular embodiments of the presentinvention of a new and useful fiber composite, it is not intended thatsuch references be construed as limitations upon the scope of thisinvention except as set forth in the following claims.

We claim:
 1. A composite down-hole tool comprising: a plurality offibers, said fibers extending along at least a first fiber plane and asecond fiber plane, said first fiber plane and said second fiber planebeing arranged perpendicular; a matrix material substantially fillingthe area between and around the plurality of fibers; and wherein thedown-hole tool is spherical or cylindrical and substantially all of saidplurality of fibers extend substantially straight and uninterruptedbetween opposed sides of the spherical or cylindrical shape down-holetool.
 2. The down-hole tool according to claim 1 having a density lessthan about 1.8 g/cc.
 3. The down-hole tool according to claim 1 having adensity of from between about 1.0 g/cc and about 1.8 g/cc.
 4. Thedown-hole tool according to claim 1 having uniform compressive strength.5. The down-hole tool according to claim 1 wherein the compressivestrength of the down-hole tool is different in the direction of saidfirst fiber plane from said second fiber plane.
 6. The down-hole toolaccording to claim 1 further comprising a third fiber plane arrangedparallel to said first fiber plane and having a third fiber direction,said first fiber plane having a first fiber direction being 90 degreesoffset from said third fiber direction.
 7. The down-hole tool accordingto claim 1 further comprising a third fiber plane and a fourth fiberplane arranged parallel to said first fiber plane, said first fiberplane having a first fiber direction, said second fiber plane having asecond fiber direction, said third fiber plan having a third fiberdirection and said fourth fiber plane having a fourth fiber direction,said first fiber direction, being offset by 60 degrees from said thirdfiber direction and said fourth fiber direction being offset by 60degrees from said third fiber direction.
 8. The down-hole tool accordingto claim 1 having a fiber volume from between about 15% and about 55%.9. The down-hole tool according to claim 1 having a fiber volume frombetween about 30% and about 40%.
 10. The down-hole tool according toclaim 1 having a compressive strength factor greater than about 80 ksi.11. The down-hole tool according to claim 1 having a tensile strengthfactor greater than about 220 ksi.
 12. The down-hole tool according toclaim 1 wherein said plurality of fibers include one or more of PANbased carbon fibers, E glass fibers or S glass fibers.
 13. The down-holetool according to claim 1 wherein said matrix comprises epoxy orpolyimide.
 14. The down-hole tool according to claim 1 wherein saidplurality of fibers includes radially extending fibers,circumferentially extending fibers and axially extending fibers.
 15. Thedown-hole tool according to claim 1 having a diameter of from betweenabout 0.5 to about 8.0 inches.
 16. A composite down-hole tool comprisinga plurality of layers of fabric each layer comprises a plurality offibers woven in two dimensions; a matrix material substantially fillingan area between adjacent fibers and between adjacent fabric layers; andwherein the down-hole tool having a spherical or cylindrical shape. 17.The tool of claim 18 wherein the fabric layers constructed from morethan one sized fiber tows, size of the tows range from 1000 to 24000.18. The tool of claim 18 wherein the matrix material comprises at leastone of an epoxy, phenolic, polyimide, pitch and combinations thereof.19. The tool of claim 18 wherein the matrix material comprises areinforcement, the reinforcement comprises at least one of single walledcarbon nanotube, multi-walled carbon nanotubes and combinations thereof.20. The tool of claim 21 wherein the matrix material comprises no morethan five percent by weight of the resin.
 21. The tool of claim 18wherein the fabric layer may comprise one of a twill style weave, aplain weave or a unidirectional weave.